The present work deals with the design development and design validation of special purpose pneumatic tool to optimize the steps in assembly and consequently production process. An attempt is made to develop a pneumatic tool that uses power of compressed air to generate a force enough to press the stem seal and the collet, collet cup collectively. Detailed calculations of section properties of various members of the tool assembly are carried out. Calculation for force to be generated is done by considering possibilities i.e. hydraulic generation and pneumatic. Prior to fabrication, detailed CAD modeling of each component of assembly is carried out using CATIA V5 software which gives a correct perception of the assembly and its components. Fabrication of each component of the assembly is carried out by various manufacturing processes as Grinding, milling, drilling. To enhance surface hardness induction hardening is carried out. Close correlation between the calculated and generated force validates the design.

1. See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/280488708
Development and Design Validation of Pneumatic Tool for Stem Seal & Collet
Fitment of SL-90 Engine Cylinder Head
Article · July 2011
CITATIONS
0
READS
73
4 authors, including:
Some of the authors of this publication are also working on these related projects:
Design and development of transport Utility Vehicles View project
Vikas Deulgaonkar
Marathwada Mitra Mandal's College of Engineering
20 PUBLICATIONS 30 CITATIONS
SEE PROFILE
All content following this page was uploaded by Vikas Deulgaonkar on 27 July 2015.
The user has requested enhancement of the downloaded file.

2. International Journal of Manufacturing Science and Engineering • International Science Press • Vol. 2 • No. 1 • January-June 2011
Development and DesignValidation of Pneumatic Tool for Stem Seal & Collet Fitment of SL-90 Engine Cylinder Head. 53
Development and Design Validation of Pneumatic Tool for Stem Seal
& Collet Fitment of SL-90 Engine Cylinder Head.
DeulgaonkarVikas Radhakrishna1
, Shivang Bhatnagar2
, Ashish Karve3
andVarun Kelkar4
1
Senior Lecturer, Mechanical Engineering, MMCOE, Pune.
2,3,4
(Under Graduate students: Mechanical Engineering Department, MMCOE Pune).
Abstract: The present work deals with the design development and design validation of special purpose pneumatic tool to
optimize the steps in assembly and consequently production process. An attempt is made to develop a pneumatic tool that uses
power of compressed air to generate a force enough to press the stem seal and the collet, collet cup collectively. Detailed calculations
of section properties of various members of the tool assembly are carried out. Calculation for force to be generated is done by
considering possibilities i.e. hydraulic generation and pneumatic. Prior to fabrication, detailed CAD modeling of each component
of assembly is carried out using CATIA V5 software which gives a correct perception of the assembly and its components.
Fabrication of each component of the assembly is carried out by various manufacturing processes as Grinding, milling, drilling.
To enhance surface hardness induction hardening is carried out. Close correlation between the calculated and generated force
validates the design.
Keywords: Collet, pneumatic tool, pneumatic circuit analysis, inertia, reaction calculations.
1. INTRODUCTION
The need to design of present specialized tool arises from
the application of the assembled engine. The products
include diesel engines, irrigation pump sets, and diesel
generating sets. These engines are used in agricultural
machinery, construction and material handling machinery,
marine applications and military applications. A detailed
survey on the shop floor reflected the need of this tool on
the assembly station of SL-90 engine. In the design phase
present drawings gave following dimensions: Figure 1: Top & Front View of Cylinder Head
In next step the calculations of the net force required
for compressing the springs are carried out in following
manner as discussed below:
Spring material: EN47/ASTM 6150
Composition: 50Cr V4, Flat spring steel, high carbon,
oil tempered hard drawn.
Spring stiffness: (K)K = Force/Deflection. From the
data available,
Inner Spring Stiffness is Kinner = 8.03 N/mm & Outer
Spring Stiffness is Kouter = 18.36 N/mm.
Net deflection δ of the Inner spring: 16.7mm & Net
deflection (δ) of outer spring: 21.35mm.
No. of springs used = 4. Two springs are used together
in parallel i.e. 1 set of inner and outer spring together as
F = F1 + F2 (springs in parallel); F1 and F2 are forces
exerted by outer and inner springs respectively.

3. International Journal of Manufacturing Science and Engineering • International Science Press • Vol. 2 • No. 1 • January-June 2011
54 DeulgaonkarVikas Radhakrishna, Shivang Bhatnagar,Ashish Karve andVarun Kelkar
F = (K1 * d1) + (K2 * d2)
Where, K1 = Stiffness of outer spring, K2 = Stiffness of
inner spring,
δ1 = Deflection of outer spring, δ2 = Deflection of inner
spring.
Substituting the values,
F = (18.36 * 16.7) + (8.03 * 21.35)
= 306.612 + 171.441 = 478.053 N ~ 48kg
Pneumatic cylinder bore diameter db calculations:
Available air pressure:
Pmax = 7kg/cm2
and Pmin = 5 – 2kg/cm2
F = P * A = 48.73 = (3 * 10–2
) * (Π/4) * db
2
db
2
= 2068.165 db = 45.48mm ~ standard bore
diameters: 32, 40, 50, 60, 80
Available: 80mm
Hence pneumatic cylinder of make, FESTO: DCV–
80 (bore diameter) –160(stroke) –PPV – A is selected.
2. DESIGN OF PLATES, COLUMNS, LOCKING
MECHANISM
3. REACTIONS ON TOP PLATE
Material of the plate: Mild steel
Density of Mild Steel = 7.85 g/cm3
Volume of the plate
= 3.72 * 106
mm3 = 3720 cm3
Total volume of holes made in the plate = {21.205cm3
(4 corner holes) + 11.403cm3
(4 holes surrounding
pneumatic bore) + 47.412cm3
(Pneumatic piston bore)} =
80.32cm3
.
Net volume of remaining MS = 3720 – 80.32 = 3639.68
cm3
Mass of remaining MS; Density = Mass/Volume
Mass = 3639.68 * 7.85 = 28.571 Kg = 280.28 N
Calculation of safe diameter of the pillar:
The design of the support column is carried out as under
Material: MS
Considering moment about A: ∑ aM = 0 (Clockwise
= +ve)
2xRb × 400 = 348.95 × 200 i.e. Rb = 87.2375 N = Rd
Considering moment about B: ∑ bM = 0 (Clockwise
= +ve)
2xRa × 400 = 348.95 × 200 i.e. Ra = 87.2375 N = Rc
Assuming diameter of column = 30mm for initial
analysis and Factor of safety (F.O.S) = 1.5
A r e a o f c o l u m n = ( Π/4) * d2
= 706.85 mm2
Theoretical
yield strength of MS = 250MPa
Selection of safe diameter
Force/Area = Syt /F.O.S = {(87.2375/9.81)}/706.85 =
Syt /1.5
Syt = 0.018 kg/mm2
i.e.0.018 kg/mm2
<0.25 kg / mm2
Hence, 30mm diameter pillars are safe.
Figure 2: Base Plate with Locating Mechanism (Left)
& Pillar (Right)
4. DESIGN OF STEM SEAL FITMENT FIXTURE
Stem Seal is used to prevent the passing of inlet and exhaust
gases to the springs above the cylinder head. They are fitted
on the inlet and exhaust valve rods. The use of this tool
reduces time as both the stem seals are fitted at same time
unlike the current system of individual seal fitting. It is
more reliable as the same pressure is applied for all the
stem seals.

4. International Journal of Manufacturing Science and Engineering • International Science Press • Vol. 2 • No. 1 • January-June 2011
Development and DesignValidation of Pneumatic Tool for Stem Seal & Collet Fitment of SL-90 Engine Cylinder Head. 55
Figure 3: Drawing of Stem Seal & Final Design of Fixture for Stem Seal Fitment
5. DESIGN OF COLLET FITMENT FIXTURE:
Collets along with collet cup are used to connect springs
to the valve rods to restrict the opening of inlet and exhaust
valves. The designs considered for tool of collet fitment.
(a) Tool with single step: For fitting the collets in
the groove on the valve rods so as to retain the
springs at the groove of valve rod, this was the
first design under consideration.
Figure 3: Sketch of Tool with Single Step (Left) & Tapered Step (Right)
(b) Tool with tapered step: It consisted of a taper 15
degree with base diameter same as inner diameter
of collet cup. The expansion of the collets could
not be enclosed properly.
(c) Tool with in-built spring: To eliminate the above
difficulties the smaller spring was used to let the
collets expand and then the spring gradually
presses them and locates to groove. But it faced
manufacturing complexities.

5. International Journal of Manufacturing Science and Engineering • International Science Press • Vol. 2 • No. 1 • January-June 2011
56 DeulgaonkarVikas Radhakrishna, Shivang Bhatnagar,Ashish Karve andVarun Kelkar
Figure 4: Locking Mechanism (Left) & Tool with the
Built-in Spring (Right)
Finally a design which consists of hole instead of step
where the collets can be placed after the collet cup and
springs are compressed below the groove was successfully
tested several times.
Figure 5: Final Collet Fitment Tool Design (Left) & the
Final Assembly (Right)
6. CONCLUSION
The work was commenced with the thorough study of
various possible tool designs before freezing the design.
Calculation of force for compressing two springs was a
major contributing task in pneumatic tool design.
Determination of support column diameter is carried out
using elementary strength of machine elements concepts.
Selection of frame material & medium for application of
force (pneumatic) for compressing the springs for fixing
of the collet into the groove of valve rod is carried out
with the help of available references. The air required for
the pneumatic operation is also made available on the work
station without any separate arrangement for air supply.
CAD model was prepared taking into consideration
suggestions & effective communication with the operator.
Calculations of reactions at the support from the loading
diagram are also carried out to freeze the support frame
design. The use of this tool reduces labor fatigue, operating
time, reduced steps as two operations are performed on
the same machine and enhances the productivity of the
assembly unit.
References
[1] Pinches, “Industrial Fluid Power”, Prentice Hall Publication-
1997.
[2] FESTO Manual on Pneumatic Application and FESTO
Product Catalogue.
[3] “FRL Units and Direction Control Valves Operation”,
www.wisc-online.com.
[4] ISO-1219, “Fluid Systems and Components”, Graphic
Symbols.
[5] “Company Profile”, www.kirloskar.com/.
[6] E. Andrew Parr,Andrew Parr, “Hydraulics and Pneumatics:
ATechnician’s and Engineer’s Guide”, Butterworth-Heineman-
1991.
[7] James.F.Simpson, PP “Pneumatic System Contamination”.
[8] James.F.Simpson, PP., “Using ISO Standards for Pneumatic
Engineering Applications”.
[9] Tom kreher, PP “Pneumatic Filter Flow Factors - WP #43”.
[10] Tom kreher, PP“Cylinder Dynamics &Cylinder Possibilities”.
[11] J. Dyn. Sys., Meas, “A High Performance Pneumatic Force
Actuator System: Part I—Nonlinear Mathematical Model”,
Control, September 2000, 122, Issue 3, 416 (10 pages).
[12] S. Messner, J. Schaible, H. Sandmaier and R. Zengerle,
“Three-Way Silicon Microvalve for PneumaticApplications
with ElectrostaticActuation Principle”, 2, Number 2, pp.89-
96, DOI: 10.1007/s10404-005-0048-5.
[13] Verrelst, Björn; Van Ham, Ronald, “Second Generation
Pleated Pneumatic Artificial Muscle and its Robotic
Applications”, 20, Number 7, 2006, pp.783-805(23).
[14] Caldwell, D.G.; Medrano-Cerda, G.A.; Goodwin, M,
“Control of Pneumatic Muscle Actuators”, Issue Date: Feb
1995,15.
[15] Design Data Book; PSG College of Technology, Coimbatore.

6. View publication statsView publication stats